Direct methanol fuel cells (DMFC) are appealing as a power source for portable devices as they do not require recharging with an electrical outlet. However, the DMFC technology is confronted with the high crossover of methanol fuel from the anode to the cathode through the currently used Nafion membrane, which not only wastes the fuel but also poisons the cathode platinum catalyst. With an aim to overcome the problems encountered with the Nafion membrane, this dissertation focuses on the design and development of new polymeric membrane materials for DMFC and a fundamental understanding of their structure-property-performance relationships. Several polymeric blend membranes based on acid-base interactions between an aromatic acidic polymer such as sulfonated ploy(ether ether ketone) (SPEEK) and an aromatic basic polymer such as heterocycle tethered poly(sulfone) (PSf) have been explored. Various heterochylces like nitro-benzimidazole (NBIm), 1H-Perimidine (PImd), and 5-amino-benzotriazole (BTraz) have been tethered to PSf to understand the influence of pKa values and the size of the hetrocycles. The blend membranes show lower methanol crossover and better performance in DMFC than plain SPEEK due to an enhancement in proton conductivity through acid-base interactions and an insertion of the heterocycle side groups into the ionic clusters of SPEEK as indicated by small angle Xray scattering and TEM data. The SPEEK/PSf-PImd blend membrane shows the lowest methanol crossover due to the larger size of the side groups, while the SPEEK/PSf-BTraz blend membrane shows the highest proton conductivity and maximum power density. To further investigate the methanol-blocking effect of the heterocycles, N,N’-Bis- (1H-benzimidazol-2-yl)-isophthalamide (BBImIP) having two amino-benzimidazole groups bonded to a phenyl ring has been incorporated into sulfonated polysulfone (SPSf) and SPEEK membranes. With two 2-amino-benzimidazole groups, which could greatly increase the proton transfer sites, and three phenyl rings, which are compatible with the aromatic polymers, the BBImIP/SPSf and BBImIP/SPEEK blend membranes show suppressed methanol crossover and increased fuel cell performance in DMFC. Novel sulfonated copolymers based on poly(aryl ether sulfone) (SPS-DP) that exhibit low methanol crossover have been synthesized and explored as a methanol-barrier center layer in a multilayer membrane configuration having SPEEK as the outer layers. These multilayer membranes exhibit better performance in DMFC than plain SPEEK and Nafion 115 membranes due to suppressed methanol crossover. To address the issue of incompatibility between the new hydrocarbon-based membranes synthesized and the Nafion ionomer used in the catalyst layer in fabricating membrane-electrode assemblies (MEAs), the MEAs have been fabricated with the SPEEK membranes and 10 to 30 % SPEEK ionomer in the catalyst layer. These MEAs exhibit better performance in DMFC compared to the MEAs fabricated with the SPEEK membranes and Nafion ionomer in the catalyst layer due to lower interfacial resistance. / text

Direct methanol fuel cells (DMFC) are being investigated for use as low-power electrochemical energy conversion devices. These types of fuel cells can be useful for portable electronics. The polymer electrolyte membrane plays a critical role in the overall performance of DMFC. The commercially available membrane, Nafion, suffers from high methanol permeability and a resulting methanol crossover from the anode to the cathode; it is also expensive. Accordingly, alternative membrane materials, such as sulfonated hydrocarbons, are intensively pursued for DMFC. For example, sulfonated poly (ether ether ketone) (SPEEK) and sulfonated polysulfone (SPsf) are two such candidates. This thesis focuses first on a simple synthesis method for a cross-linked sulfonated polysulfone membrane. Sulfonated polysulfone (Psf) membranes, with high IEC (1.4 - 2.2 meq/g), were characterized by nuclear magnetic resonance spectroscopy (NMR), proton conductivity, and water uptake. The degree of sulfonation was calculated by NMR and verified by acid-base titration analysis. Although the membranes showed good proton conductivity, they suffered from excessive swelling at high temperatures. Furthermore, the post-sulfonation of a carboxyl-substituted polysulfone (Psf-COOH) was carried out with trimethylsilyl chlorosulfonate, and solubility issues of the Psf-COOH in chlorinated solvents led to difficulty in controlling the degree of sulfonation (DS) and in purification. Accordingly, this approach to cross-linking sulfonated polysulfone was rejected as a viable method. This thesis then focused on the investigation of the mechanical properties of acid-base blend membranes based on SPEEK and heterocycle-tethered Psf and cross-linked membranes based on SPEEK that were previously reported by our group; these membranes were known to exhibit good performance in DMFC. However, the assessment of the mechanical stability of any new membranes developed is critical for their practical viability in DMFC. Accordingly, the mechanical strength and ductility of these membranes were investigated and compared for various membrane compositions. The acid-base blend membranes investigated consisted of SPEEK (acidic polymer) and a heterocycle-tethered Psf (basic polymer); for example, blends consisting of SPEEK and amino-benzimidazole-tethered Psf (SPEEK/Psf-ABIm) and SPEEK and benzotriazole tethered Psf (SPEEK/Psf-Btraz) were investigated. The cross-linked SPEEK was made by Friedel-Craft acylation with Psf-COOH (DS = 1 or 2). The two blend membranes showed superior mechanical properties compared to Nafion 115 and comparable to plain SPEEK. The crosslinked membranes showed good mechanical properties and better strength than Nafion 115, but they were more brittle than both Nafion 115 and plain SPEEK. Further optimization of cross-linking conditions is necessary to produce the best performing membrane. / text

Hydrogen is considered to be the most promising energy carrier of the 21st century due to its high energy density and sustainability. The chemical energy of hydrogen can be directly converted into electricity by means of electrochemical devices called fuel cells. Proton exchange membrane fuel cells (PEMFC) are the most preferred type of fuel cells due to their low operating temperatures enabling fast and easy start-ups and quick responses to load changes. One of the most important components of a PEMFC is the proton conducting membrane. The current membrane technology is based on perfluorosulfonic acid membranes and the most common one being Nafion. Although these membranes have good thermal and chemical stability, mechanical strength and high proton conductivities, they tend to dehydrate very fast at high temperatures and low relative humidity leading to poor fuel cell performances. Moreover, the high manufacturing cost of these membranes limits the mass-production of PEMFC&amp / #8217 / s in near future. The aim of this study is to develop alternative PEMFC membranes that have sufficient thermal and chemical stability, mechanical strength and comparable proton conductivity and fuel cell performances with Nafion membranes at relatively low cost. In this context, organic-inorganic composite membranes and blends were developed. A relatively cheap and commercially available polymer, polyether ether ketone, (PEEK), was chosen as the membrane matrix for its high thermal and mechanical stability and improvable proton conductivity via post-sulfonation. The proton conductivity of SPEEK membrane (at DS 68%) was 0.06 S/cm at 60&deg / C, and this conductivity was further increased to 0.13 S/cm with the introduction of zeolite beta crystals as inorganic fillers. The conductivity of a SPEEK blend (25wt% SPES-75wt% SPEEK) membrane was 0.08 S/cm at 90&deg / C. In PEMFC performance tests, 397 mA/cm2 was obtained for SPEEK membrane (DS 56%) at 0.6V for a H2/O2 PEMFC working at 1 atm and 80&deg / C. This result is promising when compared to the performance of Nafion 112&reg / of 660mA/cm2 under same conditions. These results are welcomed since the target for commercially viable alternate membranes are reached.

The environmentally unsafe by-products (CO2, H2S, NOx and SO2 for example) of using carbon-based fuels for energy generation have paved the way for research on cleaner, renewable and possibly cheaper alternative energy production methods. Hydrogen gas, which is considered as an energy carrier, can be applied in a fuel cell setup for the production of electrical energy. Although various methods of hydrogen production are available, sulphur-based thermochemical processes (such as the Hybrid Sulfur Process (HyS)) are favoured as alternative options for large scale application. The SO2 electrolyser is applied in producing H2 gas and H2SO4 by electrochemically converting SO2 gas and water. This study focused firstly on the evaluation of the performance of the SO2 electrolyser for the production of hydrogen and sulphuric acid, using commercially available PFSA (perfluorosulfonic acid) (Nafion®) as benchmark by evaluating i) various operating parameters (such as cell temperature and membrane thickness), ii) the influence of MEA (membrane electrode assembly) manufacturing parameters (hot pressing time and pressure) and iii) the effect of H2S as a contaminant. Subsequently, the suitability of novel PBI polyaromatic blend membranes was evaluated for application in an SO2 electrolyser. The parametric study revealed that, depending on the desired operating voltage and acid concentration, the optimisation of the operating conditions was critical. An increased cell temperature promoted both cell voltage and acid concentration while the use of thin membranes resulted in a reduced voltage and acid concentration. While an increased catalyst loading resulted in increased cell efficiency, such increase would result in an increase in manufacturing costs. Using electrochemical impedance spectroscopy at the optimised operating conditions, the MEA manufacturing process was optimised with respect to hot press pressure and time, while the effect of selected operating conditions was used to evaluate the charge transfer resistance, ohmic resistance and mass transport limitations. Results showed that the optimal hot pressing conditions were 125 kg.cm-2 and 50 kg.cm-2 for 5 minutes when using 25 and 10 cm2 active areas, respectively. The charge transfer resistance and mass transport were mostly influenced by the hot pressing procedure, while the ohmic resistance varied most with temperature. Applying the SO2 electrolyser in an alternative environment to the HyS thermochemical cycle, the effect of H2S on the SO2 electrolyser anode was investigated for the possible use of SO2 electrolysis to remove SO2 from mining off-gas which could contain H2S. Polarisation curves, EIS and CO stripping were used to evaluate the transient voltage response of various H2S levels (ppm) on cell efficiency. EIS confirmed that the charge transfer resistance increased as the H2S competed with the SO2 for active catalyst sites. Mass transport limitations were observed at high H2S levels (80 ppm) while the ECSA (electrochemical surface area obtained by CO stripping) showed a significant reduction of active catalyst sites due to the presence of H2S. Pure SO2 reduced the effective active area by 89% (which is desired in this case) while the presence of 80 ppm H2S reduced the active catalyst area to 85%. The suitability of PBI-based blend membranes in the SO2 electrolyser was evaluated by using chemical stability tests and electrochemical MEA characterisation. F6PBI was used as the PBI-containing base excess polymer which was blended with either partially fluorinated aromatic polyether (sFS001), poly(2,6-dimethylbromide-1,4-phenylene oxide (PPOBr) or poly(tetrafluorostyrene-4-phosphonic acid) (PWN) in various ratios. Some of the blend membranes also contained a cross-linking agent which was specifically added in an attempt to reduce swelling and promote cross-linking within the polymer matrix. The chemical stability of the blended membranes was confirmed by using weight and swelling changes, TGA-FTIR and TGA-MS. All membranes tested showed low to no chemical degradation when exposed to 80 wt% H2SO4 at 80°C for 120 h. Once the MEA doping procedure had been optimised, electrochemical characterisation of the PBI MEAs, including polarisation curves, voltage stepping and long term operation (> 24 h) was used to evaluate the MEAs. Although performance degradation was observed for the PBI membranes during voltage stepping, it was shown that this characterisation technique could be applied with relative ease, producing valuable insights into MEA stability. Since it is expected that the SO2 electrolyser will be operated under static conditions (cell temperature, pressure and current density) in an industrial setting (HyS cycle or for SO2 removal), a long term study was included. Operating the SO2 electrolyser under constant current density of 0.1 A cm-2 confirmed that PBI-based polyaromatic membranes were suitable, if not preferred, for the SO2 environment, showing stable performance for 170 hours. This work evaluated the performance of commercial materials while further adding insights into both characterisation techniques for chemical stability of polymer materials and electrochemical methods for MEA evaluation to current published literature. In addition to the characterisation techniques this study also provides ample support for the use of PBI-based materials in the SO2 electrolyser. / PhD (Chemistry), North-West University, Potchefstroom Campus, 2015

The environmentally unsafe by-products (CO2, H2S, NOx and SO2 for example) of using carbon-based fuels for energy generation have paved the way for research on cleaner, renewable and possibly cheaper alternative energy production methods. Hydrogen gas, which is considered as an energy carrier, can be applied in a fuel cell setup for the production of electrical energy. Although various methods of hydrogen production are available, sulphur-based thermochemical processes (such as the Hybrid Sulfur Process (HyS)) are favoured as alternative options for large scale application. The SO2 electrolyser is applied in producing H2 gas and H2SO4 by electrochemically converting SO2 gas and water. This study focused firstly on the evaluation of the performance of the SO2 electrolyser for the production of hydrogen and sulphuric acid, using commercially available PFSA (perfluorosulfonic acid) (Nafion®) as benchmark by evaluating i) various operating parameters (such as cell temperature and membrane thickness), ii) the influence of MEA (membrane electrode assembly) manufacturing parameters (hot pressing time and pressure) and iii) the effect of H2S as a contaminant. Subsequently, the suitability of novel PBI polyaromatic blend membranes was evaluated for application in an SO2 electrolyser. The parametric study revealed that, depending on the desired operating voltage and acid concentration, the optimisation of the operating conditions was critical. An increased cell temperature promoted both cell voltage and acid concentration while the use of thin membranes resulted in a reduced voltage and acid concentration. While an increased catalyst loading resulted in increased cell efficiency, such increase would result in an increase in manufacturing costs. Using electrochemical impedance spectroscopy at the optimised operating conditions, the MEA manufacturing process was optimised with respect to hot press pressure and time, while the effect of selected operating conditions was used to evaluate the charge transfer resistance, ohmic resistance and mass transport limitations. Results showed that the optimal hot pressing conditions were 125 kg.cm-2 and 50 kg.cm-2 for 5 minutes when using 25 and 10 cm2 active areas, respectively. The charge transfer resistance and mass transport were mostly influenced by the hot pressing procedure, while the ohmic resistance varied most with temperature. Applying the SO2 electrolyser in an alternative environment to the HyS thermochemical cycle, the effect of H2S on the SO2 electrolyser anode was investigated for the possible use of SO2 electrolysis to remove SO2 from mining off-gas which could contain H2S. Polarisation curves, EIS and CO stripping were used to evaluate the transient voltage response of various H2S levels (ppm) on cell efficiency. EIS confirmed that the charge transfer resistance increased as the H2S competed with the SO2 for active catalyst sites. Mass transport limitations were observed at high H2S levels (80 ppm) while the ECSA (electrochemical surface area obtained by CO stripping) showed a significant reduction of active catalyst sites due to the presence of H2S. Pure SO2 reduced the effective active area by 89% (which is desired in this case) while the presence of 80 ppm H2S reduced the active catalyst area to 85%. The suitability of PBI-based blend membranes in the SO2 electrolyser was evaluated by using chemical stability tests and electrochemical MEA characterisation. F6PBI was used as the PBI-containing base excess polymer which was blended with either partially fluorinated aromatic polyether (sFS001), poly(2,6-dimethylbromide-1,4-phenylene oxide (PPOBr) or poly(tetrafluorostyrene-4-phosphonic acid) (PWN) in various ratios. Some of the blend membranes also contained a cross-linking agent which was specifically added in an attempt to reduce swelling and promote cross-linking within the polymer matrix. The chemical stability of the blended membranes was confirmed by using weight and swelling changes, TGA-FTIR and TGA-MS. All membranes tested showed low to no chemical degradation when exposed to 80 wt% H2SO4 at 80°C for 120 h. Once the MEA doping procedure had been optimised, electrochemical characterisation of the PBI MEAs, including polarisation curves, voltage stepping and long term operation (> 24 h) was used to evaluate the MEAs. Although performance degradation was observed for the PBI membranes during voltage stepping, it was shown that this characterisation technique could be applied with relative ease, producing valuable insights into MEA stability. Since it is expected that the SO2 electrolyser will be operated under static conditions (cell temperature, pressure and current density) in an industrial setting (HyS cycle or for SO2 removal), a long term study was included. Operating the SO2 electrolyser under constant current density of 0.1 A cm-2 confirmed that PBI-based polyaromatic membranes were suitable, if not preferred, for the SO2 environment, showing stable performance for 170 hours. This work evaluated the performance of commercial materials while further adding insights into both characterisation techniques for chemical stability of polymer materials and electrochemical methods for MEA evaluation to current published literature. In addition to the characterisation techniques this study also provides ample support for the use of PBI-based materials in the SO2 electrolyser. / PhD (Chemistry), North-West University, Potchefstroom Campus, 2015